Modular rack for transporting and horizontally storing gas cylinders

ABSTRACT

A modular rack for storing gas cylinders includes a plurality of vertical posts spaced from one another. A plurality of sleeves are removably sleeved onto the posts. At least one tray is removably attached to this post and sleeves. The tray includes a plurality of cradles, or spaced apart beams, adapted to at least partially retain a horizontally positioned gas cylinder therein.

BACKGROUND OF THE INVENTION

The present invention generally relates to racks and carts for gas tanks, such as compressed gas cylinders. More particularly, the present invention relates to a modular rack or cart which is assembled for storing and transporting such gas cylinders.

There are many gases which are stored in cylindrical tanks for later use. Many of these gases are compressed. Such compressed gas cylinders may contain compressed oxygen for medical or manufacturing purposes, helium, such as for use in children's' balloons, and other gases, such as those used in welding and the like. Due to the high pressure and the dangers associated with this high pressure, and at times the volatile nature of the contents of the cylinder, OSHA and DOT have set forth safety regulations and placed certain guidelines on the storage and transportation of such compressed gas cylinders. It will be appreciated to those skilled in the art that given the compressed gas within the cylinder, if a cylinder were to fall over and the outlet valve be damaged or broken, the compressed gas would escape and the cylinder could act as a rocket, causing much damage. Accordingly, the proper storage and transportation of these cylinders is very important.

Compressed gas cylinder carts and racks have been designed and manufactured by various companies for many years. However, they are all comprised of welded steel construction. This presents many drawbacks. First, manufacturing of these units is very expensive as it requires a skilled welder to weld all the joints of the cart or rack. Moreover, shipping and storage of these units is very costly as they occupy a large volume.

There do exit modular racks, such as that illustrated and described in U.S. Pat. No. 5,676,263 to Chang. However, these racks are not configured to store and transport compressed gas cylinders. For example, the modular rack of Chang includes trays having a wire rack for supporting articles thereon. However, the trays are not configured to securely store compressed gas cylinders thereon, or any other object capable of rolling due to the fact that the wires or rods of the trays are so close to one another that the compressed gas cylinders would easily roll to the left or to the right. Given the danger associated with dropping a compressed gas cylinder, such racks would be totally unacceptable for transportation and storage purposes and would not meet the safety regulations set forth by OSHA and DOT.

Accordingly, there is a continuing need for a modular rack or cart for storing gas cylinders which can be transported in a disassembled state so as to save on shipping and storage, yet is easily assembled with little skill and simple tools. The present invention fulfills these needs and provides other related advantages.

SUMMARY OF THE INVENTION

The present invention resides in a modular rack or cart adapted to store compressed gas cylinders and the like. The modular rack of the present invention generally comprises a plurality of vertical posts spaced from one another. Typically, the vertical posts consist of four posts spaced from one another in a generally rectangular configuration. At least one tray is removably attached to the vertical posts. The tray has a plurality of positioning tubes for receiving the vertical posts therethrough. The tray further includes a plurality of cradles each adapted to at least partially retain a horizontally positioned gas cylinder therein. Typically, a plurality of trays removably attached to the posts in spaced apart relation. The tray comprises generally parallel outer frame members having a plurality of elongated cross-beams extending therebetween. A pair of the cross beams are spaced apart from one another less than an outer diameter of the gas cylinder to be stored so as to form a gas cylinder retaining cradle.

A plurality of sleeves are removably sleeved on the posts and configured to engage the positioning tubes of the at least one or more trays. In a particularly preferred embodiment, the sleeves comprise first and second portions which are snap-fit to one another surrounding the posts. The vertical posts typically include a plurality of spaced apart annular retaining grooves formed on an outer surface thereof. The sleeves include radially inward protrusions adapted to be received within the annular retaining grooves of the posts. The sleeves are configured to be matingly received within the positioning tubes. In one particularly preferred embodiment, a lower portion of the sleeve is of a wider diameter than an upper portion of the sleeve. The positioning tube defines a correspondingly tapered inner surface so that a frictional engagement is formed therebetween.

In one embodiment, the plurality of posts comprise a first set of posts and a second set of posts. The first and second sets of posts are connected end to end with the post connector disposed between each connected set of posts. The post connector has a generally cylindrical configuration with a ledge extending radially outward intermediate the ends thereof. The ends of the post connector are configured to be removably inserted into open ends of the posts. Wheels may be operably associated with each post so as to transport the gas cylinders.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention. In such drawings:

FIG. 1 is a front perspective view of an assembled modular rack embodying the present invention and having compressed gas cylinders stored thereon;

FIG. 2 is an exploded perspective view, illustrating components for assembling a first tray, in accordance with the present invention;

FIG. 3 is a front perspective view illustrating the connection of a sleeve onto a post, in accordance with the present invention;

FIG. 4 is a front perspective view illustrating the assembly of a second tray to the rack;

FIG. 5 is a perspective view of an assembled four tray rack embodying the present invention; and

FIG. 6 is a partially exploded perspective view illustrating the addition of wheels and another set of vertical posts to the rack, in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in the accompanying drawings, for purposes of illustration, the present invention is directed to a modular rack or cart, generally referred to by the reference number 10. A benefit of the rack of the present invention is that it is designed so as to be modular and assembled in simple fashion, typically only utilizing a hammer to assemble the pieces to one another. That is, various components thereof are removably attached to one another such that the rack tends to be fairly compact when not assembled for storage and transport. As described above, such racks or carts are typically offered as a single unit, requiring a significant amount of welds between the various metallic components thereof. Due to the large space requirements, such prior art containers are costly to ship and store in a warehouse, etc. The rack of the present invention overcomes these disadvantages.

With reference now to FIG. 1, the rack 10, in one embodiment of the invention, includes a plurality, typically four posts 12-18, which are oriented vertically and spaced apart from one another, typically forming a generally rectangular configuration. A plurality of trays 20 are removably attached to the posts, as will be more fully described herein. In FIG. 1, the rack 10 includes eight spaced-apart trays 20. However, it will be appreciated by those skilled in the art that the number of trays 20 can vary between racks depending upon the need. The trays 20 are configured so as to securely retain a compressed gas cylinder 22 thereon when the gas cylinder 22 is disposed in a generally horizontal position, as illustrated. The gas cylinder 22 may comprise any compressed gas cylinder, such as metallic tanks having compressed air, oxygen, or other gases. Many of these gas cylinders 22, particularly those used in the medical industry, are provided in generally uniform widths. For example, E cylinders and the like are approximately 4.5 inches in outer diameter. An M6 cylinder is slightly less than 3½ inches in outer diameter. However, it will be appreciated by those skilled in the art with the description provided below that the rack 10 of the present invention can be modified so as to accommodate different sized gas cylinders 22.

With reference now to FIGS. 2-4, the rack 10 comes disassembled. In order to assemble the rack 10, the posts 12-18 are spaced apart from one another, typically in rectangular configuration. A plurality of sleeves, at least one for each post 12-18 are provided. These sleeves are removably attached to each vertical post 12-18 and adapted to engage the portion of the tray 20.

With particular reference now to FIG. 3, each sleeve is typically comprised of first and second portions 24 and 26 which are configured to snap-fit to one another surrounding the post 14. As such, at least one of the portions or halves 24 and/or 26 includes a male projection 28 which is configured to be received within a corresponding female recess 30 of the other portion 24 or 26. In a particularly preferred embodiment, each portion 24 and 26 includes male projections 28 and female recesses 30 so that a secure snap-fit connection can be made between the two portions 24 and 26.

In a particularly preferred embodiment, with continuing reference to FIG. 3, each post 12-18 includes a plurality of spaced apart annular retaining grooves 32 formed on an outer surface thereof. Each sleeve portion 24 and 26 includes radially inward protrusions 34 adapted to be received within the annular retaining grooves 32 of the posts 12-18. Thus, the assembled sleeve portions 24 and 26 snap-fit to one another will remain at the desired location on the posts 12-18. Moreover, the sleeves will be positioned at the same relative height on each post 12-18. The sleeves, as will be more fully described herein, serve as stops for the trays 20.

With reference now to FIG. 2, each tray 20 includes a positioning tube 36 attached thereto and corresponding to one of the posts 12-18. Typically, a positioning tube 36 is integrally formed or otherwise affixed to each corner of the tray 20, as illustrated in FIG. 2. Each positioning tube 36 is generally tubular and includes a through-hole 38 through which the post 12-18 is inserted. The inner diameter of the positioning tube 36 is of a greater than the outer diameter of the post 12-18. Thus, the tray 20 can be easily slid over the post 12-18. The assembled sleeve portions 24 and 26 are configured to be matingly received within the positioning tubes 36. In a particularly preferred embodiment, the sleeves are of a wider diameter at a lower portion thereof than an upper portion, so as to have an outer taper. The positioning tubes define a correspondingly tapered inner surface such that the assembled sleeve fits within the positioning tube and engages it so as to serve as a stop. A friction fit is formed as the tray 20 is pressed downwardly, such as striking the tray 20 with a rubber mallet or hammer, to form a tight connection. With reference now to FIG. 4, this process is repeated in order to add additional trays 20 to the vertical posts 12-18. FIG. 5 illustrates a rack 10 having four trays 20 assembled in spaced-apart relation.

With reference again to FIG. 3, in order to provide additional stability, leveling feet 40 extend from the bottom of each post 12-18. Instead of being leveling feet, these feet 40 may comprise tabs 40 having an aperture 42 through which a fastener, such as a bolt, can be passed through and into a floor or the like so as to securely hold the rack 10 in place without fear of tipping over.

With reference now to FIG. 6, in some cases, the rack 10 needs to be mobile so as to transport the gas cylinders 22, or to be easily moved from one location to another. Typically, the posts 14-18 are hollow tubes. Tubular shafts 44 of a caster wheel 46 have a smaller outer diameter than the inner diameter of the posts 12-18, so as to be removably received therein. The shaft portion 44 may include protrusions, such as an annular ring or the like which serves as a grip, or the ends of the shafts 44 may be externally threaded and the open ends of the post 12-18 internally threaded so as to receive the wheel shafts 44 therein. Typically, however, the shafts 44 of the caster wheels 46 include an annular ring 48 or the like which slips into and engages an internal groove 50 of the post 12-18.

With continuing reference to FIG. 6, in order to create a rack 10 of additional height so as to assemble additional trays thereon, the vertical posts 12-18 can be made of a greater length. Alternatively, a second set of posts 52-58 are provided which are connected end to end with posts 12-18. One way of accomplishing this is by providing a post connector 60 which interconnects the top end of post 12-18 to the bottom end of post 52-58. In a particularly preferred embodiment, the post connector 60 has a generally cylindrical configuration with ends 62 and 64 having an outer diameter which is less than that of the inner diameter of the post 12-18 and 52-58. A ledge 66 extending radially outward intermediate the ends 62 and 64 of the post connector 60 provides a stop or contact surface for the end of post 12-18 and the corresponding post 52-58. The ends 62 and 64 of the post connector 60 may be externally threaded and received within internal threads of the post 12-18 and 52-58 as well. In this manner, a taller rack with additional trays, such as that illustrated in FIG. 1, is provided.

With reference again to FIG. 2, the trays 20 as described above, are configured to retain or cradle horizontally disposed gas cylinders 22 thereon. The gas cylinders 22, for safety purposes, must not be able to be easily moved from their stored position. For example, if the gas cylinders 22 were placed on a conventional storage rack, the cylinders 22 could roll from left to right, possibly falling from the rack and presenting a safety hazard. Due to the fact that the gas cylinders 22 are filled with compressed gas, breaking the nozzle end, or puncturing the gas cylinder 22 can either cause an explosion, or the gas cylinder 22 serving as a torpedo or rocket as the compressed gas uncontrollably leaves the gas cylinder 22. Accordingly, DOT and OSHA have strict regulations regarding the storage and transportation of such gas cylinders.

In accordance with these safety regulations, the tray 20 of the present invention is configured to securely retain and store such gas cylinders 22. Each tray 20 includes generally parallel outer frame members 68 and 70. A plurality of elongated cross beams 72-82 extend between the outer frame members 68 and 70. The number of cross beams 72-82 depends upon the length of the outer frame member 68 and 70, and the desired number of gas cylinders 22 to be stored on each tray 20. The cross beams 72-82 are spaced apart from one another less than an outer diameter of the gas cylinder so as to form a gas cylinder retaining cradle therebetween, as illustrated in FIG. 1. For example an E cylinder is approximately 4.4 inches in diameter. Thus, in order to store such cylinders on the rack 10, adjacent cross beams 72 and 74 (or any other combination of adjacent cross beams) must be disposed such that their adjacent-most surfaces are spaced apart less than 4.4 inches. However, the cross beams cannot be too close to one another, or the cylinder tanks 22 will have a propensity to roll and not be securely retained in the cradle formed by the adjacent cross beams 72 and 74. For example, cross beams 72 and 74 are preferably spaced apart from one another such that their adjacent edges are 4.0 to 4.3 inches apart from one another. It is desirable to have a large amount of the lower surface, below a mid-line of the gas tank 22, positioned below the plane of the adjacent cross beam 72 and 74, such that the gas cylinders 22 are securely retained therebetween. Accordingly, the cross beam 72 and 74 should be positioned such that 49% or less of the body of the gas cylinder 22 is disposed below the cross beams 72 and 74. More typically, 25% to 45% of the gas cylinders 22 is disposed below the plane of the adjacent cross beam 72 and 74. If 50% or more of the gas cylinder 22 were able to be disposed below the plane of the adjacent cross beam 72 and 74, the gas cylinder 22 would fall between the cross beams 72 and 74. Accordingly, the cross beams 72 and 74 are disposed a fraction of an inch less than the outer diameter of the gas cylinder tank 22 so as to retain the gas cylinder 22 therebetween. For example, M6 cylinders are approximately 3.4 inches in diameter. Thus, cross beams 72 and 74 would be spaced apart from one another to create a gap between 3.0 and 3.3 inches in diameter. The trays 20 illustrated herein include six cross beams, thus being able to accommodate up to five gas cylinders 22 on each tray 20. However, as mentioned above, the number of cross beams can be altered so as to accommodate fewer or more gas cylinders 22.

Although several embodiments have been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims. 

1. A modular rack for storing gas cylinders, comprising: a plurality of vertical posts spaced apart from one another; at least one tray having a plurality of positioning tubes for receiving the vertical posts therethrough, the at least one tray further including a plurality of cradles each adapted to at least partially retain a horizontally positioned gas cylinder therein; and a plurality of sleeves removably sleeved on the posts and configured to engage the positioning tubes of the at least one tray.
 2. The modular rack of claim 1, wherein the plurality of vertical posts comprise four posts in spaced apart relation.
 3. The modular rack of claim 1, wherein the vertical posts include a plurality of spaced apart annular retaining grooves formed on an outer surface thereof.
 4. The modular rack of claim 3, wherein the sleeves include radially inward protrusions adapted to be received within the annular retaining grooves of the posts.
 5. The modular rack of claim 1, wherein the sleeves comprise first and second portions snap-fit to one another surrounding the post.
 6. The modular rack of claim 1, wherein the sleeves are configured to be matingly received within the positioning tubes.
 7. The modular rack of claim 6, wherein lower portions of the sleeves are of a wider diameter than upper portions of the sleeves, and wherein the positioning tubes define correspondingly tapered inner surfaces.
 8. The modular rack of claim 1, wherein the at least one tray comprises a plurality of trays removably attached to the posts and sleeves in spaced apart relation.
 9. The modular rack of claim 1, wherein the at least one tray comprises generally parallel outer frame members having a plurality of elongated cross-beams extending therebetween.
 10. The modular rack of claim 9, wherein a pair of the cross-beams are spaced apart from one another less than an outer diameter of the gas cylinder so as to form a gas cylinder retaining cradle.
 11. The modular rack of claim 1, including wheels operably associated with each post.
 12. The modular rack of claim 1, wherein the plurality of posts comprise first and second sets of posts connected end to end with a post connector disposed between each connected set of posts.
 13. The modular rack of claim 12, wherein the post connector has a generally cylindrical configuration with a ledge extending radially outward intermediate ends thereof, the ends of the post connector configured to be removably inserted into open ends of the posts.
 14. A modular rack for storing gas cylinders, comprising: four vertical posts spaced apart from one another in a generally rectangular configuration; a plurality of sleeves removably sleeved on the posts, each sleeve comprising first and second portions snap-fit to one another surrounding the post; a plurality of trays having a plurality of positioning tubes for receiving the vertical posts therethrough and configured to removably engage the sleeves such that the trays are disposed in vertical spaced relation on the posts, the trays including generally parallel outer frame members having a plurality of cross-beams extending therebetween, adjacent cross beams spaced apart from one another sufficiently so as to cradle and retain a horizontally positioned gas cylinder therebetween.
 15. The modular rack of claim 14, wherein the vertical posts include a plurality of spaced apart annular retaining grooves formed on an outer surface thereof, and wherein the sleeves include radially inward protrusions adapted to be received within the annular retaining grooves of the posts.
 16. The modular rack of claim 14, wherein lower portions of the sleeves are of a wider diameter than upper portions of the sleeves, and wherein the positioning tubes define correspondingly tapered inner surfaces.
 17. The modular rack of claim 14, including wheels operably associated with each post.
 18. The modular rack of claim 14, wherein the plurality of posts comprise first and second sets of posts connected end to end with a post connector disposed between each connected set of posts.
 19. The modular rack of claim 18, wherein the post connector has a generally cylindrical configuration with a ledge extending radially outward intermediate ends thereof, the ends of the post connector configured to be removably inserted into open ends of the posts. 